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The project report focuses on the study of crack propagation and life expectancy of metal components, particularly in railway tracks, under cyclic loading conditions. It outlines the problem of predicting the life of cracked components and aims to develop a faster method for estimating their life expectancy through research and calculations based on fracture mechanics. The report includes objectives, methodology, results, and expected outcomes, highlighting the importance of understanding crack behavior for safety and operational efficiency.

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Shadhin Sudhershan
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15 views20 pages

projectppt-220726150643-29fbfda2 (1)

The project report focuses on the study of crack propagation and life expectancy of metal components, particularly in railway tracks, under cyclic loading conditions. It outlines the problem of predicting the life of cracked components and aims to develop a faster method for estimating their life expectancy through research and calculations based on fracture mechanics. The report includes objectives, methodology, results, and expected outcomes, highlighting the importance of understanding crack behavior for safety and operational efficiency.

Uploaded by

Shadhin Sudhershan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Project report

on
A Study on
Crack Propagation and Life expectancy.

PRESENTED BY:
PUSHKRAJ RANE (18162152)
RISHIKESH SALI (18162158)
VISHAL SANGALE (18162161)

Guided by:
Dr. Sandhya Jadhav
INDEX
• Introduction

• Problem statement

• Objectives of Study

• Literature review

• Methodology

• Research and Calculation

• Results obtained

• Outcomes through the research.


Introduction

• Cracks commonly occur in engineered parts and can significantly reduce their
ability to withstand load. Cracks typically form around pre-existing flaws in a part.
They usually start off small and then grow during operational use.

• A crack in a part will grow under conditions of cyclic applied loading, or under a
steady load in a hostile chemical environment. Crack growth due to cyclic loading
is called fatigue crack growth and is the focus of this study. Crack growth in a
hostile environment is called environmental crack growth and is not included in
the this case study project.
• The analysis of fatigue crack growth relies on the concepts of fracture mechanics.
Problem statement

• It is usually really difficult for anyone to predict the life of a particular metal
element considering it to be damaged due to presence of crack which are
visible on the surface.

• Due to presence of cracks, the strength of the component as whole gradually


decreases as the propagation of crack is expected due to the constantly acting
fatigue loads on the entire component and prediction of the direction of crack
expansion is also really difficult.

• A crack on a railway track is extremely dangerous as it may cause a huge


accident, hence after locating a crack it is necessary to estimate the life of the
component in order to know how long it could be in a working condition.
• Incase of an railway track crack, the expansion and crack propagation
rate is extremely high.

• Due to extremely high cyclic/fatigue loading on the tracks, the cracks


seem to propagate at faster rate hence quick action has to be taken to
determine the remaining life of the component in order to take
necessary actions.
Objectives of the Study

• To simulate and try to find a faster way to find the life


expectancy of cracked metal component under the allowable
factor of safety in working condition.

• Taking a case of a railway track crack and analyzing the effect


and growth of the crack due to constantly acting fatigue load.
Literature review
 Research paper on ‘Fatigue crack growth’
• The following study takes various loads and stresses in account along
with various stress ratios and it also establishes a relationship between
crack growth and the constant cyclic loading.

• The experimentation is done a metal plate with naturally visible crack


due to surface flaws, when the component is put to its usual operations,
the usual stresses start acting but, due the presence of crack, the life of the
component is gradually reduced and the growth rate of the crack is
minutely observed and the acting loads are also closely monitored.
• On the basis of obtained results of the crack growth in a certain time
under certain fatigue loading, a relationship of crack growth to
loading is established which makes it easier to determine the
remaining life of the component before it fails in the factor of safety
and becomes un-operational.

• Although the exact results from experimentation are not provided,


but the study does use previous research in fracture mechanics to
determine the life of the component and gives a brief theoretical
explanation on how the crack propagation/expansion takes place so
that the same method could be used to determine the same in other
cases by making the necessary changes such as material properties,
acting loads and the Factor of safety.
Research paper on
Rail fatigue crack propagation
 This Research paper focuses mainly on the
cracks and its effects on railway tracks.

The study through various methods and based on earlier


research and assumptions tries to effectively determine the behavior of cracks
when the wheels of trains make surface contact with them in a very fast speed.

 In this study mostly finite element method is used to determine the effect of
loading at significant points on the crack in the component(track).

Using predefined Relations and formulae, the crack propagation is tracked with
the difference in the speed of train which increases/ decreases the time that load
acts on the railway track.
Methodology
• Data collection.

• Theoretical study of the concepts of fracture mechanics

• Research, Calculation and data interpretation.

• Detailed Analysis of obtained results.

• Co-relation of the results and concepts with case study.

• Conclusion of the Study.


Research and Calculations
 The research on Crack Propagation and its growth was carried out
in a systematic order by initially determining all the factors
necessary for the Calculation of life of the metal having a visible
surface crack.
 Some of the Crucial Factors that were considered necessary after
thorough research for the determination of the results of this
study were,
Stress Intensity Factor (Kmax)

Paris Equation
Crack Length Prediction

 The data required for the calculation were selected and the
standard were values were assumed or selected wherever
necessary by taking reference of the earlier research papers.
 The calculation for the life expectancy of a metal with a crack
started with calculating the stress intensity followed by
consideration of the forces acting on the specimen, substitution
of data in Paris equation and calculating the final Crack length
after completion of a given No. cycles of cyclic load.
 The crack length obtained at the end is then used to check when
the specimen would fail and its Life expectancy.
Results in graphical method:

 The results of the graphical method could be shown through a


graph,
where the Increasing no. of cycles (N) are denoted on X axis,
whereas the length of crack which increases simultaneously is
shown on Y axis.
 The result obtained is a smooth rising curve.
 The points plotted are,
ai which denotes initial crack length which in this case is the notch
length i.e 5 mm.
ao which denotes the increase in crack length, here its obtained as 20
mm.
af which denotes the final crack length (45 mm).
 The graph further rises and shows the breaking point of the
material.

 The slopes obtained from the curve are also used in the process
of calculation in the numerical approach.
Results obtained
 The main focus of research was to understand the phenomenon
of crack propagation and fracture mechanics and hence for the
purpose of research a MS block was kept under cyclic loading and
a notch was made purposely for the crack to propagate further.

 The obtained result were as follows;


for a crack with initial crack length (notch length) was taken
5mm.

 The dimension of the MS block were 50*50*10 mm, with a 5 mm


notch on the center of edge on the face.

 A larger initial crack length was purposely selected in order to


show the intensity of crack growth because the presence of a
micro crack and the 1st phase of crack expansion is concurrent
but extremely slow.
Results obtained
 A small load of 25 N was selected for a large no. of cycles which was
assumed for initial calculations as 2000 cycles.

 After completion of a given no. of cycles the crack fully propagates into
the material through out its length, hence the final crack length
excluding the notch is 45mm.

 Both numeric and graphical method were used for calculation of the
failure point (Nf) i.e. the no. of cycles the block could withstand before
failure.

 This Final crack length was used to further calculate the point of failure
of the component and the No. of cycles before failure.

 The Failure point (Nf) i.e. the no. of cycles the component could survive
before failure was 120 cycles.
DRAWING AND ANALYSIS

Mild steel block of size Stress concentration at


50 x 50 x 10 position of notch causing
cracking of material
Project Timeline

1. Data collection and research till September.

2. Theoretical study and literature review in October and November.

3. Research and Calculations to be done in November and December 2020.

4. Study and review of the obtained result to be done in December- January.

5. Conclusion of study and preparation of black book in February and


march 2021.
Expected outcomes

 Toprovide a detailed understanding about the concepts of


fracture mechanics and the behavior of cracks and its
effect on usual operations.

 Tofind ways to calculate the life of component having


cracks more effectively by using pre-existing relations,
concepts for taking necessary actions faster.
Thank you

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